Flexible packages having reusable pull-tab openers

ABSTRACT

A package comprising a bag having lines of weakness and a pull-tab opener secured to the bag proximate to the lines of weakness, the pull-tab opener having a pull-tab opening integral therewith, wherein the pull-tab opening is designed to be hooked with hooking means. In one embodiment, a sealed container is provided comprising a flexible bag having lines of weakness with at least one product disposed within the bag. In a preferred embodiment, the pull-tab opener is a reusable pull-tab opener.

RELATED APPLICATIONS

This Application is a divisional under 37 C.F.R. 1.53(b) of U.S. patentapplication Ser. No. 10/695,716, filed on Oct. 29, 2003, now pending,which is a continuation under 37 C.F.R. 1.53(b) of U.S. patentapplication Ser. No. 10/032,297, filed Dec. 21, 2001, now issued as U.S.Pat. No. 6,698,928; both of which applications are incorporated hereinby reference.

FIELD

The present invention relates to flexible packages and, in particular,the present invention relates to flexible packages having reusablepull-tab openers.

BACKGROUND

Compressible personal care articles, such as incontinence garments,disposable diapers, feminine hygiene products, and so forth, are inwidespread use worldwide. These items are typically sold in multiplequantities and are contained in bags or packaging composed of flexiblepolymer materials.

However, such packaging can be quite difficult to open. As a result,perforations are often added as an opening aid. Typical perforatedopening features require a consumer to search the bag for openinginstructions. Once the feature is located, the consumer must then pushone or more fingers through the plastic film to initiate the opening. Inmany instances, a tool, such as a knife or scissors, is required toseparate the perforations. Other features require the consumer to graspor pinch a portion of the bag to separate the perforation and initiatethe opening. However, it is widely recognized that such grasping orpinching is quite difficult for consumers who have limited or reducedhand strength and dexterity due to age, physical illness or fatigue.

Yet another problem with this type of packaging is the inability toreseal a package once it has been opened. This can lead to the contentsspilling out during storage and/or transport.

For the reasons stated above, and for other reasons stated below whichwill become apparent to those skilled in the art upon reading andunderstanding the present specification, there is a need in the art forpackaging that is easier to open and reseal.

SUMMARY

The present invention provides a package comprising a bag having linesof weakness and a reusable pull-tab opener secured to the bag proximateto the lines of weakness, the pull-tab opener having a pull-tab openingintegral therewith. In one embodiment, the lines of weakness areperforations that are substantially parallel and concealed by thepull-tab opener. In this embodiment, a slit or third perforation line issubstantially perpendicular to the perforations and connects thesubstantially parallel perforation lines at one end. In anotherembodiment, the perforations comprise one or more lines that angletowards each other, but do not necessarily meet. In other embodiments,the perforations form a substantially V-shape or U-shape. In theseembodiments, the pull-tab can alternately be located at an area ofminimum distance apart, a perforation junction, or area of maximum bendof a curve, depending on the perforation configuration.

The pull-tab opener (hereinafter “pull-tab”) and bag are made from anytype of flexible material, such as a polymeric plastic film, paper orpaper composites and the like. As such, the bag is understood to notonly include conventional bags, but also other types of flexibleproducts, such as mailing envelopes, and so forth. The pull-tab canfurther function as a label having opening instructions to assist aconsumer in locating and operating the opening feature. In someembodiments, the pull-tab may be a paper or paper-based material. Thepackage may be a pre-formed bag or a bag formed together with thepull-tab. The products inside the package may or may not be foldedand/or individually wrapped. Such products include, but are not limitedto, disposable diapers, incontinence products, feminine hygieneproducts, or any other type of consumer product packagable in flexiblebags, including, but not limited to, cat litter, food products,including pet food products, further including other types of consumerproducts, such as office supplies, books, magazines, household products,and so forth.

In a preferred embodiment, the present invention further provides apackage comprising a bag having a flap section defined by lines ofweakness in the bag; and a pull-tab secured to and extending beyond theflap section, wherein the pull-tab is designed to be used to open andreseal the bag.

The present invention also includes a method of using a pull-tabcomprising hooking a pull-tab opening located on a pull-tab, thepull-tab secured to a bag having perforations; and with the pull-tabopening, pulling the pull-tab away from the bag to create a bag opening.The method further comprises accessing one or more articles through thebag opening; and closing the bag opening with the pull-tab, the pull-tabhaving reusable adhesive. The method can further comprise hooking thepull-tab opening again to expose the bag opening.

The present invention further includes a kit containing any embodimentof the present invention together with a plurality of articles andinstructions for opening the bag and using the articles.

The design and location of the specially-designed pull-tab provides aneasy-to-use opening aid in conjunction with the lines of weakness, forease in opening the package. By arranging the pull-tab and perforationsin this manner, a consumer now need only gently tug on a convenientlylocated pull-tab opening in order to cause the perforations to tearapart. The novel design of the lines of weakness and pull-tabcombination provides an advantage over conventional methods of openingbags by eliminating the need to use a significant pinching or graspingforce to open. The pull-tab opening in the pull-tab also provides anadvantage over pull-tabs without any type of opening that are not onlyhard to locate, but can be difficult to hang onto while opening thepackage.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified perspective view of a package comprising a baghaving perforations and a reusable pull-tab located on top of theperforations in one embodiment of the present invention.

FIG. 2 is a simplified schematic illustration of the reusable pull-tabof FIG. 1 in one embodiment of the present invention.

FIG. 3 is a simplified perspective view of a package comprising a baghaving perforations and an alternative pull-tab located on top of theperforations in one embodiment of the present invention.

FIG. 4 is a simplified perspective view of a package comprising a baghaving perforations and another alternative pull-tab oriented on top ofthe perforations in one embodiment of the present invention.

FIG. 5 is a simplified perspective view of a package comprising a baghaving two sets of perforations and two alternative pull-tabs located ontop of the two sets of perforations in one embodiment of the presentinvention.

FIG. 6 is a simplified perspective view of the package in FIG. 1 beingopened with the reusable pull-tab in one embodiment of the presentinvention.

FIG. 7 is a simplified perspective view of the package in FIG. 1 beingresealed with the reusable pull-tab in one embodiment of the presentinvention.

FIG. 8 is a simplified perspective view of a package comprising a baghaving a handle, perforations, and an alternative pull-tab in oneembodiment of the present invention.

FIG. 9 is a simplified schematic illustration of the alternativepull-tab and a portion of the perforation configuration of FIG. 8 in oneembodiment of the present invention.

FIG. 10 is a simplified perspective view of a package comprising a baghaving perforations and an alternative pull-tab located at a perforationjunction in one embodiment of the present invention.

FIG. 11 is a simplified perspective view of a package comprising a baghaving perforations and another alternative pull-tab located at analternative perforation junction in one embodiment of the presentinvention.

DETAILED DESCRIPTION

In the following detailed description of the preferred embodiments,reference is made to the accompanying drawings which form a part hereof,and in which is shown by way of illustration specific preferredembodiments in which the inventions may be practiced. These embodimentsare described in sufficient detail to enable those skilled in the art topractice the invention, and it is to be understood that otherembodiments may be utilized and that mechanical, procedural, and otherchanges may be made without departing from the spirit and scope of thepresent inventions. The following detailed description is, therefore,not to be taken in a limiting sense, and the scope of the presentinvention is defined only by the appended claims, along with the fullscope of equivalents to which such claims are entitled.

As used herein, the terminology such as vertical, horizontal, top,bottom, front, back, end and sides are referenced according to the viewspresented. It should be understood, however, that the terms are usedonly for purposes of description, and are not intended to be used aslimitations. Accordingly, orientation of an object or a combination ofobjects may change without departing from the scope of the invention.

The term “pull-tab” or “pull-tab opener” as used herein, refers to aseparate piece of material attached or partially attached to a packagethat can be pulled on to expose or create an opening in the package. Theportion of the “pull-tab” that is pulled on is referred to herein as a“pull-tab opening” which can be of any suitable size and shape. In oneembodiment, the “pull-tab opening” is a hand-sized opening, which islarge enough to accommodate all the fingers of even the largest hand. Ina preferred embodiment, the pull-tab opening is a “finger-sizedopening,” which is understood to be at least large enough for one fingerof a small or young individual (or an object about the size of onefinger) to pass through, but not so large as to encourage a consumer toplace more than three fingers through (or an object about the size ofthree fingers), although this may occur with consumers having relativelysmall fingers as compared with an average-sized consumer. As such, thepull-tab opening can assume any reasonable shape, size and geometrydepending on the particular application.

The term “line of weakness” as used herein, refers to any region or areaof weakened material, preferably having a length, but not necessarily adefined width. A “line of weakness” can include linear and non-linearpatterns, such as curvilinear patterns of weakness, or other shapes,such as circles, rectangles, and so forth. A line of weakness includes aperforation or other series of cuts, a thinning or breakage orseparation of material, or a strip of a different kind of materialbridging between adjacent portion of material, that is more easily tornor broken than the adjacent portions, and which allows the user ormanufacturer to separate the adjacent portions along the line ofweakness. A line of weakness can further include a single extended slitor cut.

A flexible package having a pull-tab is described herein. As shown inFIG. 1, the flexible package 100 is comprised of a bag 102 and apull-tab 104. In this embodiment, the pull-tab opener, i.e., pull-tab104 is a strip of material covering a portion of two adjacent panels.The pull-tab 104 is positioned over and operates in conjunction withperforations 125 a, 125 b and 125 c cut into the bag 102. A pull-tabopening 109 is contiguous with the pull-tab 104 as shown. The pull-tab104 can optionally function as a label and contain instructions and/orinformation 111, such as instructions designed to help a user find thepull-tab opening 109. In FIG. 1, the instructions include an arrowpointing towards the pull-tab opening 109 together with the words, “PULLHERE TO OPEN,” although the invention is not so limited. Any suitablemarkings and/or wording can be used to convey the opening and/or otherinstructions. In other embodiments, all instructions/information 111 arelocated on the package 102 instead of or in addition to the pull-tab104.

The bag 102 further includes a back panel 108 as shown. The front panel106 and back panel 108 are juxtaposed and joined together along theirside edges by welds or side seams 110. When the bag 102 is filled witharticles 105, the bag 102 expands and side sections 103 and 107 arecreated in the front and back panels, 106 and 108, respectively. Eachside section 103 and 107 is about one-half the width of the articles105. The bag 102 further has a top edge 135 and a bottom edge 137 asshown.

At one end (hereafter referred to as the “top end”) of the bag 102,i.e., nearest the top panel 101, there is a top gusset formed from folds114 a and 114 b that is integral in one piece with panels 106 and 108.The bag 102 is also expandable near the end opposite the top end, i.e.,near the bottom end, through use of bottom side gussets (not shown)located on panels 106 and 108. As shown in FIG. 1, the gusset istypically a triangular-shaped reinforcement, with the outer folds 114 aand 114 b forming a triangle shape with the top edge 135. The size ofthe gusset varies, depending on the size and number of articles 105being packaged, as the gusset is designed to expand or unfoldsufficiently to accommodate the articles 105 within. In one embodiment,the gusset is sealed only along the side seam 110, and not along itsouter folds 114 a and 114 b. In another embodiment, such as for largerpackages 100, the gusset is also sealed to the bag 102 diagonally alongthe outer folds 114 a and 114 b which is referred to in the art as a“chevron” or reinforced seal.

The dimensions of the bag 102 vary, depending on the type and number ofarticles 105 being packaged. Generally, the bag 102 has a rectangularstructure, although the invention is not so limited. In one embodiment,the bag 102 is about 24 cm in height (i.e., length), 30 cm in width, andwhen filled with articles 105, about 12 cm in depth. Although not shownin the figures herein, the corners of the packages, such as the cornerdefining the transition from the side section 103 to the front panel106, are slightly curved. Other conventional construction features ofthe bag 102 are understood by those skilled in the art and will not bediscussed in detail herein. Essentially any type of flexible bag knownin the art can be used, and further information on material choices isgiven below.

As noted above, the perforations and pull-tab are located on twoadjacent panels. In other embodiments, the perforations and/or pull-tabsare located on only one panel of the bag 102 (See, for example, FIG. 4).(In yet other embodiments described in FIGS. 8-11, the perforations arelocated on two adjacent panels, but the pull-tab is secured to only oneof the panels). In the embodiment shown in FIG. 1, the pull-tab 104 isoriented substantially vertically along the front panel 106 andsubstantially horizontally along the top panel 101. In this embodiment,the lines of weakness comprise two substantially parallel lines ofperforations 125 a and 125 b located beneath the pull-tab 104, with anadditional perforation 125 c, running cross-wise to connect theperforation lines 125 a and 125 b at the end proximate to the pull-tabopening 109. As will become apparent from the description herein, theprecise location and orientation of the pull-tab 104, including thepull-tab opening 109, are not important, as long as it is locatedappropriately to provide the means to separate the perforations so thata user can successfully open the bag 102 and access the contents within.In a preferred embodiment, the pull-tab 104 is a reusable pull-tabhaving reusable securing means on at least a portion to allow thepull-tab 104 to be used repeatedly to open and reseal the package 100.

The bag 102 and pull-tab 104 can be made from any one of a wide varietyof materials that are known in the art to be sufficiently flexible toaccommodate the desired number of articles 105. This includes, but isnot limited to, polymeric plastic, foils, paper, paper composites, andthe like, or a combination thereof. In one embodiment the material isselected from the group consisting of polyethylene, polypropylene,polyester, nylon, and any combination thereof.

With regard to the bag 102, the material should have sufficient strengthto hold and contain the articles 105 within without breaking and withoutexcessive bulging or stretching of the film material. Such materialsinclude polyethylene, polypropylene, polyester, nylon, and the like, aswell as any combination thereof. In one embodiment, the material is alow density polyethylene (LDPE) film. In another embodiment, thematerial is a LDPE/LLDPE (linear low density polyethylene) filmlaminate. In yet another embodiment, the material is a LDPE/MDPE (mediumdensity polyethylene) film laminate, a LDPE/HDPE (high densitypolyethylene) film laminate or the like. In another embodiment apolyethylene/polypropylene combination is used. In a specificembodiment, the material is a polyethylene film or film laminate havinga thickness of about between about one (1) and four (4) mils (about0.025 to 0.1 mm).

The pull-tab 104 can also be made from any of the aforementionedmaterials, but needs to be of sufficient strength to withstand thepulling forces experienced, particularly during the initial opening.Furthermore, polyethylene is known to have elastic-like properties andin one embodiment is combined with a polyester or polypropylene materialto reduce the amount of elongation. Although some stretching may stilloccur during use of such a blended material, preferably the stretchingis minimal so as not to affect the ability of the user to open andreseal the package. In most embodiments, elongation during use will notexceed about 10%. The use of nylon provides a slightly stiffer pull-tab,which is particularly useful when the pull-tab opening 109 is relativelysmall, such as a finger-sized opening. In one embodiment, the pull-tab104 is a laminate material, coated with a stiffener or varnish toenhance its ability to withstand stretching. In another embodiment, thepull-tab is a paper-based product. In embodiments in which adhesive isapplied to the pull-tab 104, it operates essentially as a type of tapeand may be referred to as an “adhesive tape.”

In one embodiment, the pull-tab 104 is a pressure-sensitive labelpartially secured to the package with suitable securing means known inthe art. Such securing means can be permanent or temporary and caninclude, but is not limited to, permanent adhesive, reusable adhesive, acombination of permanent and reusable adhesive, thermal bond(s),ultrasonic bond(s), spot weld(s), i.e., thermal weld point(s), a stitchor stitches, strip weld(s), tack(s) formed by crimping, and so forth,including any combination thereof. In embodiments in which adhesive(s)are used, adhesive deadener can be added in the area of the pull-tabopening 109 (FIG. 2) to prevent the pull-tab 104 from attaching to thebag 102 in that location. In this way, the pull-tab opening 109 caneasily be hooked by the consumer. In other embodiments, this area canalternately contain no securing means. In yet other embodiments, thesecuring means is patterned, so that the pull-tab 104 is secured incertain locations, such as with patterned adhesive, as is known in theart.

Any suitable type of securing means can be used as long as a portion ofthe pull-tab 104 remains secured to the bag 102 during the openingprocess, and preferably thereafter. In most embodiments, the securingmeans includes both permanent and temporary or reusable securing means,although the invention is not so limited. In the embodiment shown inFIG. 1, permanent securing means can be used in the area of the pull-tab104 that is located between the perforation lines 125 a, 125 b and 125c, i.e., in a flap section 130 of the bag 102. Specifically, the flapsection or flap 130, shown in dashed lines in FIG. 1, is defined onthree sides by the perforation lines 125 a, 125 b and 125 c, but is notactually created until the perforation lines 125 a, 125 b and 125 c aretorn. The remaining edge of the flap 130 is defined by a crease (notshown) which is formed when the pull-tab 104 is opened, i.e., when theperforation lines 125 a, 125 b and 125 c have been completely torn. Thecrease is located generally along an edge 132 of the pull-tab 104opposite the pull-tab opening 109. In such an embodiment, reusablesecuring means can be used outside the area of the flap 130 so that thepull-tab 104 can be used again to reseal the bag 102. The permanent andtemporary securing means can be applied directly to the bag 102 and/orto the pull-tab 104, depending on the particular application.

The type, amount, location and distribution of the securing means isprimarily dependent on the size and configuration of the perforations.Basically, the force required to initially tear the lines of weakness,which in the embodiment shown in FIG. 1 includes perforation line 125 c,and may even include a small portion of perforation lines 125 a and 125b, needs to be less than the force it would take to remove the pull-tab104 from the flap 130. In other embodiments, the initially torn line ofweakness may include a slit or cut rather than a perforation such asperforation 125 c (See 326 in FIG. 3). Once the other lines of weaknessbegin to tear, e.g., 125 a and 125 b in FIG. 1, the user typicallyapplies less force to effect tearing and the pull-tab 104 continues tostay adhered to the flap 130. In one embodiment, the perforations have astrength of between about 1600 and 2200 grams of force, depending on bagmaterial, composition and thickness. The strength of the securing meansfor the pull-tab must be sufficient to overcome the strength of aparticular set of perforations. Securing means specifications are alsodependent on the size, configuration and location of the pull-tab on thebag, and may further depend on package size and even content type, form(e.g., compressed or uncompressed), amount, size, and so forth.

In resealable embodiments, a sufficient portion of the pull-tab 104needs to be secured to the bag 102 initially so as to prevent thepull-tab 104 from coming off prematurely. However, if too much of thepull-tab 104 is secured, the consumer will have difficulty accessing thepull-tab opening. In one embodiment, at least about 60% of the pull-tabis secured to the bag 102 initially, and at least about 30% of thepull-tab 104 remains secured to the bag 102 after all the lines ofweakness have been torn. The remaining 30% that is no longer secured,i.e., is releasably secured, is available for resealing the bag opening.In other embodiments, up to about 90% is secured initially.

In the securing means described above for FIG. 1, the entire flap 130remains secure to the bag 102 during the opening process. In otherembodiments, less than all of the flap 130 is designed to remain secure.However, enough of the pull-tab 104, i.e., at least about 25 to 50%should remain secured to the bag 102 (i.e., the flap 130 in thisembodiment) to ensure that it can assist in separating the perforationswhen pulled on. Otherwise, the pull-tab 104 may come off prematurely.Conversely, if too much of the pull-tab 104 is permanently secured tothe bag 102, the bag may open at locations other than the intendedperforations. Additionally, if the pull-tab 104 is used as a carryinghandle, it is likely that the perforation lines could tear prematurelysimply from the weight of the package itself.

The reusable securing means, such as reusable adhesive, needs tomaintain its stickiness or tackiness such that the remaining portions ofthe pull-tab 104 that are not intended to remain adhered to the bag 102during opening, i.e., are releasably secured, can continue to be usedrepeatedly to reseal the bag through application of only a slightpressure by the user. However, it is understood that over time, agreater portion of the pull-tab 104 may become releasably secured,although the adhesive amount and type is designed to ensure that asufficient area remains permanently secured in order to prevent thepull-tab 104 from being pulled completely off the bag 102. Although lesspreferable, it is possible for a consumer to tear open the perforationsand continue pulling until the pull-tab is completely removed, and thenreapply the pull-tab over the opening to reseal. In an exemplaryembodiment, the adhesive is a releasable pressure sensitive adhesiveavailable from ATO Findley in Wauwatosa, Wis. and the adhesive deadeneris a talc or starch powder added to the adhesive in an amount anddistribution sufficient to prevent the adhesive from bleeding through,as is known in the art. In one embodiment, the adhesive-free or deadenedarea of the pull-tab 104 comprises about 5 to 15%, the resealablesection comprises about 35 to 75% and the permanently secured sectioncomprises about 20 to 50%.

The pull-tab opening 109 can be any suitable size that providessufficient room for a person to be able to hook a hand, finger orfingers, spoon, cane, prosthetic hook, pen or any other object throughin order to assist in opening the bag. In one embodiment, the pull-tabopening is large enough for a person to slip one to two average-sizedfingers (or the equivalent) through. In another embodiment, the pull-tabopening 109 is large enough for three-fingers or its equivalent to beslipped through. According to industry guidelines, the average indexfinger width for an adult female and adult male is about 1.9 cm (about0.75 in) and 2.3 cm (about 0.9 in), respectively. It is estimated thattwo fingers would be about 3.8 cm (about 1.5 in) and 4.6 cm (about 1.8in), respectively and three fingers would be about 5.7 cm (about 2.3 in)and about 6.9 cm (about 2.7 in), respectively. However, smallerindividuals may have finger widths much smaller, such as about 1.3 cm(about 0.5 in) or even less. In most embodiments, the pull-tab opening109 is at least about 1.3 cm (about 0.5 in) in width and/or length, butnot greater than about 7.6 cm (about three (3) in) in width and/orlength. In a particular embodiment, the opening is a circular openingabout 2.5 cm (about one (1) in) in diameter. In yet another embodiment,the pull-tab opening is much larger, i.e., up to about 15 cm (about six(6) in) or more in width and/or length so that it is large enough for aperson to slip their entire hand through.

FIG. 2 provides a close-up view of the pull-tab of FIG. 1. Dimension 210represents the length of the pull-tab 104, with Dimension 212representing the width. In this embodiment, the pull-tab 104 has alength about 2.5 times the width, although the invention is not solimited. In an exemplary embodiment, Dimension 210 is about eight (8) cm(about 3.1 in) and Dimension 212 is about five (5) cm (about two (2)in). The pull-tab opening 109 in this embodiment is encircled with aprinted ring 214 to aid the consumer in locating the pull-tab opening109. In one embodiment, the ring 214 is a different color than the restof the pull-tab 104 for easy identification. For example, the ring 214can be yellow, while the remaining portion of the pull-tab 104 is clear.Areas “A” and “B” together comprise the ring 214, with Area “C”comprising the remaining portion of the pull-tab 104. The portion of thering 214 shown in cross-hatching in FIG. 2, i.e., Area “A,” contains nosecuring means, which can include application of a securing meansdeadener onto previously-applied securing means. Area “A” may be largeror smaller, depending on the particular application. The remainingportion of the ring, Area “B,” is permanently secured to Area “C” suchas through bonding or the like. Area “C” also contains securing means,which typically includes a combination of permanent and temporary orresealable securing means. For example, the permanent securing means inArea “C” can be a strip weld (FIG. 5) or spot weld (FIG. 8) or any othertype of permanent securing means known in the art. Part or all of theremaining portion of Area “C” can contain resealable securing means,such as a resealable pressure-sensitive adhesive.

In this embodiment, Dimension 213 represents the length of Area “C” atthe point it contacts the ring 214. Dimensions 216 and 218 represent thewidth of the ring 214 and Dimension 220 represents the diameter of thepull-tab opening 109. In this embodiment, the width of the ring 214 isabout one-half the diameter of the pull-tab opening 109, although theinvention is not so limited. In the exemplary embodiment noted above,Dimensions 216 and 218 are each about 1.3 cm (about 0.5 in) andDimension 220 is about 2.5 cm (about one (1) in), with Dimension 213about 2.9 cm (about 1.1 in).

The pull-tab 109 does not need to be any particular thickness as long asit can perform the intended function. In one embodiment, the pull-tab isbetween about three (3) and four (4) mm thick, but not less than aboutone (1) mm thick, although an absolute minimum thickness is dependent ona particular application. Although the pull-tab can be made inthicknesses greater than four (4) mm, in most instances, there is nosignificant advantage gained to offset the associated increase inmaterial costs.

FIG. 3 shows an embodiment of a package 100 having an alternativepull-tab 304 with an alternatively-shaped pull-tab opening 309 proximateto the front panel 106, rather than the top panel 101 as in FIG. 1. Tworows of substantially parallel perforation lines 325 a and 325 b on thepackage 100 are concealed beneath the pull-tab 304, although viewable inthe cut-away portions shown in FIG. 3. A slit 326 that extends betweenthe perforation lines 325 a and 325 b at one end can also be seen, atthe end nearest the pull-tab opening 309. The perforation lines 325 aand 325 b and slit 326, are lines of weakness that are created accordingto methods known in the art and this process will not be discussed indetail herein. Upon being torn, the perforation lines, 325 a and 325 b,together with the slit 326, form a flap 330. The flap 330 provides theopening through which the articles 105 are accessible. A crease 327,shown in FIG. 3 as dotted lines, eventually develops in the flap oncethe perforations are fully torn, as noted above in reference to FIG. 1.Again, the crease 327 is not present before the perforations are tornand may be less pronounced or essentially disappear when the pull-tab304 is resecured to the bag 102 in between uses.

The perforation lines 325 a and 325 b can extend any suitable lengthdepending on the particular application, including the package size,strength, type of adhesive, and so forth. In most embodiments, theperforation lines 325 a and 325 b do not extend into the area of thefinger-sized grip 309, as this would not provide any additionaladvantage as an opening means in this location. In the embodiment shownin FIG. 8, the perforation lines 325 a and 325 b begin about half-way upthe front panel 106 and are substantially parallel with the side seam110. In this embodiment, the perforation lines 325 a and 325 b continueonto the top panel 101 (substantially parallel with the top edge 135),extending about one-half of the way across the width of the top panel101. In other embodiments, the perforation lines 325 a and 325 b canextend anywhere from about one-fourth to about three-fourths of thedistance across the width of a top or bottom panel (and/or up or downthe length of a front or back panel) or may be confined entirely to onepanel (See FIG. 4). In other embodiments, the perforations are orienteddifferently, are in different configurations other than substantiallyparallel lines, and/or in different locations on the package, asdiscussed below.

Distance 317 in FIG. 3 defines the distance between the two perforationlines 325 a and 325 b, which in this instance also represents the lengthof the slit 326. Distance 317 can be any suitable distance as long asthe perforation lines 325 a and 325 b can perform their intendedfunction. In most embodiments, the perforation lines 325 a and 325 b arenot so close together as to be difficult to properly manufacture nor sofar apart as to lose the ability to function properly. In oneembodiment, Distance 317 is about 75 to 90% of the width of the pull-tab304. Depending on the size of the pull-tab 304, Distance 317 can beanywhere from about 1.2 cm (about 0.5 in) to about five (5) cm (abouttwo (2) in) apart, with the pull-tab 304 made correspondingly larger orsmaller as needed or desired. In one embodiment, Distance 317 is aboutfive (5) cm and the width of the pull-tab 304 is about six (6) cm.

Other perforation configurations are possible. For example, in someembodiments, the two substantially parallel lines of perforations maystraddle a single side seam, i.e., with both parallel to the side seam,but with one line located on a front or back panel and another linelocated on a side panel, as long as the resulting opening that iscreated when the perforations are torn provides adequate access to thecontents within. The two substantially parallel lines of perforationsmay also be located on non-adjacent panels. For example, in oneembodiment, two substantially parallel lines of perforations are dividedbetween the front and back panels, with a third perforation line or slitjoining these perforations at one end, thus creating an opening greaterthan the width of the side panel. In such embodiments, the pull-tab 104can also be larger to accommodate the wider opening or can be locatedsuch that not all the perforations are concealed. (See FIGS. 8-11 forexamples of embodiments having exposed perforation lines).

FIG. 4 shows an embodiment of a package 100 having an alternativepull-tab 404 with an alternatively-shaped pull-tab opening 409, thepull-tab oriented substantially horizontally on the top panel 101 of thebag 102. In this embodiment, slit 326 shown in FIG. 3, is replaced byperforation lines 425 c, which essentially perform the same function,although the slit is believed to provide greater confidence that thelines of weakness will require less force to open. Again, the pull-tab404 can be any suitable size and secured to any suitable portion of thebag 102. In this embodiment, the pull-tab 404 and lines of weakness(perforations 425 a, 425 b and 425 c) are all confined to the top panel101. The pull-tab opening 409 in this embodiment is shown as anoval-shape, although any suitable size and shape can be used to create apull-tab opening, as noted above.

FIG. 5 shows an embodiment of a package 100 have two alternativepull-tabs 504 a and 504 b, each having a pull-tab opening, 509 a and 509b, respectively. A portion of each pull-tab 504 a and 504 b ispermanently secured to the bag 102 with strip welds 550 a and 550 b,respectively, although any suitable securing means can be used. In thisembodiment, both pull-tabs, 504 a and 504 b, are oriented substantiallyhorizontally along the package, although the invention is not solimited. Multiple pull-tabs can be oriented in any suitable directionand further do not necessarily have to be oriented in the samedirection, nor do each individual pull-tab need to be oriented in justone direction (See, for example, FIGS. 1 and 3). By providing more thanone pull-tab and perforation combination, as in this embodiment, it ispossible to provide access to separate areas of the bag 102, such aswhen two different types of products are contained within.

In this embodiment, pull-tab 504 a provides access to Area “A,” whichcontains larger-sized articles 105 a. Similarly, pull-tab 504 b providesaccess to Area “B,” which contains smaller-sized articles 105 b. Again,each pull-tab 504 a has an associated set of perforations, with pull-tab504 a having two substantially parallel perforation lines 525 a and 525b, connected by a slit 526 a located at the same end as the pull-tabopening 509 a (although a third set of perforations can alternately beused as described above in FIG. 1). Similarly, pull-tab 504 b concealstwo substantially parallel perforation lines 525 c and 525 d, connectedby a slit 526 b (or third perforation line) located at the same end asthe pull-tab opening 509 b. It should be apparent that suchmulti-pull-tab embodiments are not limited to embodiments having twosubstantially parallel lines of perforations together with a slit orthird perforation line, and can be used together with any type ofperforations, including, but not limited to, those described in FIGS.8-11 below.

FIG. 6 shows the package 100 being opened using the pull-tab 104 of FIG.1, in conjunction with perforation lines 125 a, 125 b and 125 c, toexpose articles 105 within. The result is a convenient, yet restrictedpackage opening, i.e., flap 130, as described above. As FIG. 6 shows,adhesive areas 613 and 615 are created adjacent to the perforationlines, 125 a and 125 b, respectively, when the pull-tab 104 is separatedfrom the bag. Additionally a crease is also created upon opening, asdiscussed above.

Use of the pull-tab opening of the present invention, such as thepull-tab opening 109 shown in FIG. 6, for accessing the perforationssuch as 125 a, 125 b and 125 c, simplifies the opening process,particularly for those with poor manual dexterity, such as the elderly.There is now no need to use a gripping force when attempting to tearopen perforations, or poke at the perforations, such as with a finger orknife. By simply pulling on the pull-tab opening 109 in a directiongenerally downwardly (or upwardly, depending on the orientation of thepull-tab) and away from the perforations, as shown in FIG. 6, thecompressive forces within the packaged articles are partially releasedto facilitate removal of the first articles 105 from the bag 102. Sucharticles 105 are generally stacked inside the bag 102 as shown in FIGS.1 and 6. The articles 105 may further be folded, unfolded, and/orindividually wrapped. These articles 105 include disposable absorbentarticles such as, infant diapers, feminine care products and adultincontinence garments, and so forth. By further providing the pull-tabopening 109 in the form of an easily identifiable ring or hole, aconsumer can now easily open the package 100 of the present inventionunder most any conditions, including while traveling, to access thearticles 105 contained within. This is an advantage over prior artpackages which provide only a small tab with no opening that can bedifficult to see, identify and hold on to, particularly for the elderlyand/or those with poor vision and/or manual dexterity. In someembodiments, a portion or all of the ring glows in the dark to providefurther assistance in dimly lit or dark areas.

FIG. 7 shows the package 100 being resealed by the user with thepull-tab 104. Such a step is relatively simple, requiring a person toexert only a minimal pressure on the pull-tab 104 in the area of thepull-tab opening 109 in order to secure the pull-tab 104 to the bag 102again with the adhesive. The adhesive areas 613 and 615 are reusable,preferably remaining tacky or sticky for the life of the package, i.e.,for at least a number of openings and closings equal to the number ofarticles contained within. In some embodiments, this may be just one ortwo times. In other embodiments, this can be 20 times, up to about 50 ormore times.

Many other configurations of the pull-tab opener and perforations arepossible. FIGS. 8-11 illustrate only a few of the additional forms thepresent invention can take. For example, FIG. 8 shows a package 100having a handle 802 and an alternative substantially vertical laminatedpull-tab 804 (having layers 805 a and 805 b) associated with andconcealing only a small portion of the alternative perforation lines 825a and 825 b. In the embodiment shown, the pull-tab 804 is secured to thebag 102 with a spot weld 850, although the invention is not so limited.Again, any suitable type of securing means known in the art can be used.It should be recognized that the non-parallel perforation lines shown inFIGS. 8-11 can be used with any type of flexible package, although useof this type of design may be particularly useful with larger packages.Similarly, the substantially parallel perforation lines discussed hereincan also be used with any type of package, including packages havinghandles.

In one embodiment, the perforation lines 825 a and 825 b can be broughtto a joining point or perforation junction (See FIG. 11). In analternative embodiment, the pull-tab 804 may alternately conceal only afew of the perforations or even none. In such embodiments, a small cutor slit is located beneath the pull-tab 804 (see, for example, FIG. 10)to connect the two perforation lines. In such embodiments, theperforations are non-parallel non-touching, i.e., non-intersecting lineshaving a distance of minimum separation, with the reusable pull-tablocated in the area of minimum separation, i.e., concealing thisdistance. In yet other embodiments, such as with curved perforationlines, it may be that there is essentially just one perforation linethat continues underneath the pull-tab, i.e., a U-shaped perforationline, with the pull-tab located in an area of maximum perforation bend.

In the embodiment shown in FIG. 8, the pull-tab 804 is oriented with thepull-tab opening 809 at its lower end such that the pull-tab 804 ispulled upwardly to cause the perforation lines 825 a and 825 b to tear.Upon being torn, the perforation lines, 825 a and 825 b, together withthe slit or connecting perforation line (not shown beneath the pull-tab804) define a flap 830 as described above and shown in FIG. 8. The flap830 further develops a crease line 827 once it is opened sufficiently,i.e., pulled away from the bag 102. As in the other embodimentsdescribed herein, the flap 830 provides the opening through which thearticles 105 are accessible. In FIG. 8, the perforations are primarilylocated “above” the pull-tab 104. In other embodiments, the pull-tabopening is located at the upper end of the pull-tab 804, such that it ispulled in a downwardly direction to cause the perforations to tear. Insuch embodiments, the perforations are also oriented differently, withthe bulk of the perforation lines located “below” the pull-tab 804. Inyet other embodiments, the perforation lines are located both above andbelow the pull-tab 104, such that the pull-tab 104 is pulled sideways tocreate the bag opening or flap.

The perforation lines 825 a and 825 b can be any suitable lengthdepending on the particular application, including the package size,strength, type and thickness of material, type of adhesive, and soforth. In most embodiments, the perforation lines 825 a and 825 b do notextend into the area of the finger-sized grip 809, as this would notprovide any additional advantage as an opening means in this location.In the embodiment shown in FIG. 8, the perforation lines 825 a and 825 bbegin about one-third of the way up from the bottom edge 137 of thefront panel 106 and extend upwardly and outwardly in opposite directionsat any suitable angle for any suitable distance, i.e., diagonal lines.In one embodiment, the angled portions, Distances “815 a” and “815 b”,respectively, comprise about 20-35% of the total length of theperforations 825 a and 825 b, respectively, and have angles α₁ and α₂less than 90 degrees. If angles α₁ and α₂ are too large, such thatangles α₁ and α₂ are nearly right angles, it may be difficult toinitiate tears in the remaining perforations. The remaining portion ofthe perforation lines 825 a continue up along the front panel and ontothe top panel 101 substantially parallel in a manner as described abovein reference to FIG. 3. In alternative embodiments, the diagonal portionof the perforations can comprise the complete set of perforations. Insuch embodiments, the diagonal perforation lines would likely extendfurther than shown in FIG. 8, at a different angle, and for a greaterdistance than the diagonal portion (Distances 815 a and 815 b) shown inFIG. 8.

Distance 817 in FIG. 8 defines the maximum distance between the twoperforation lines 825 a and 825 b, which in this instance alsorepresents the length of the crease 827. Distance 817 can be anysuitable distance as long as the perforation lines 825 a and 825 b canperform their intended function as discussed above. In one embodiment,Distance 817 is about 40 to 60% of the total width of the front or backpanels, 106 or 108, respectively. Depending on the size of the bag 102,Distance 817 can be anywhere from about three (3) cm (about 1.2 in) toabout 25 cm (about 10 in) apart. In the specific embodiment describedabove in which the bag 102 is about 24×30×12 cm in height, length andthickness, respectively, Distance 817 is about 15 cm.

FIG. 9 provides a close-up view of the pull-tab 804 of FIG. 8. As inFIG. 2, certain areas have securing means and other areas do not,whether it be because no securing means is present or due to applicationof a securing means deadener onto an area already having securing means.In this embodiment, Area “D” contains no securing means while Area “E”contains securing means. In one embodiment, Area “E” contains permanentsecuring means as described above. In another embodiment, only a portionof Area “E” contains permanent securing means and the remainder isreusable securing means or has no securing means. However, it isimportant that a sufficient portion of the pull-tab 104 remains securedto the package permanently during use, i.e., that the strength of thepull-tab permanent securing means is greater than that required toseparate the lines of weakness. In one embodiment, Area “E” or a portionthereof, is heat-sealed in place. In other embodiments, Area “D” mayalternately contain temporary or reusable securing means.

FIG. 9 further shows a slit 926, as described above, used to helpinitiate a tear in the perforation lines 925 a and 925 b when a userlifts the pull-tab 904. In most embodiments, the slit 926 stops beforereaching the edges of the pull-tab 904, although in the embodiment shownin FIG. 9, the slit 926 extends to the edges of the pull-tab 904. Insome embodiments, the slit 926 may even extend beyond the edges of thepull-tab 904, but generally not more than about 0.6 cm (0.25 in). If theslit 926 extends too far beyond the edges of the pull-tab 904, however,a tear could develop, thus allowing contaminants to enter the bag. Sucha tear or hole could also affect the proper performance of theperforations. In one embodiment, the slit 926 stops about 0.25 cm (0.1in) to about one (1) cm (0.39 in) from the edges of the pull-tab 804.

FIG. 9 also shows Dimensions 944 and 946. Dimension 944 extends from oneend of the pull-tab 804 to the slit 926. Dimension 946 extends from theslit 926 to the beginning of Area “A.” In this embodiment, Dimensions944 and 946 are about equal, although the invention is not so limited.Dimension 944 only need be of sufficient length to continue to adhere toa bag during the opening process. Similarly, Dimension 946 only need beof sufficient length to continue to adhere to the bag during storage,i.e., serve as a closing flap for the bag.

FIG. 10 shows an embodiment of a package 100 having another alternativepull-tab 1004 and another alternative set of perforation lines 1025 aand 1025 b. Additionally, a slit 1026 is shown in the cut-away portionof the pull-tab 1004. Upon opening, an alternative crease 1027 is formedat the upper edge of the pull-tab 1004. In a different embodiment, theperforations do not stop in the area of the pull-tab 1004 andessentially continue in one line, forming a U-shape. In yet otherembodiments, the perforations are curved in any suitable manner. Inthese embodiments, the perforations typically have an area of “maximum”bend, and the pull-tab is located in this area.

FIG. 11 shows another alternative embodiment in which thealternatively-designed perforations 1125 a and 1125 b both extendsubstantially vertically along the side sections 103 and 107,substantially parallel to the side seam 110. In this embodiment, theperforation lines 1125 a and 1125 b continue along the top panel 101 ata diagonal until they meet at a perforation junction 1150 as shown inthe cut-away portion of the pull-tab 1104, although the invention is notso limited. In one embodiment, the perforation lines 1125 a and 1125 bextend about one-quarter to one-half of the way down the side sections103 and 107. In other embodiments, the perforation configuration shownin FIG. 11 can additionally or alternately be located on the front panel106 or back panel 108. This configuration of perforations can also bereversed such that more of a spout is formed. Such a configuration canagain be located anywhere on the package 100 and can be confined to onlyone panel, if desired. FIG. 1 1 further shows an alternative pull-tabopening 1 109, which is essentially a full-sized hand grip, but again,is not intended to be used as a carrying handle.

As noted above, the pull-tab does not necessarily need to be made fromthe same type or strength of material as the bag, as it may not need tohave a tensile strength as high as the tensile strength of the bag. Useof a thinner material for the pull-tab in these instances can help tokeep seal temperatures lower and is also more economical. In otherinstances, it is important to consider the nature of the articles beingpackaged. For example, with compressed packaging, the pull-tab,particularly at the point of attachment with the bag, needs to be ableto withstand the existing compression forces, and may require a highertensile strength than the bag and/or particularly strong securing means.Additionally, the perforations are necessarily stronger with compressedpackaging as compared with uncompressed packaging. As a result, thepull-tab securing means needs to be strong enough to overcome thegreater force required to tear open the perforations with this type ofpackaging.

In one embodiment, pull-tabs are made from a roll of plastic coated withadhesive and detachably secured to a releasable material, such assilicon-coated release paper known in the industry. The plastic materialis then printed with any needed markings, such as the ring and/or wordsdescribed above and die cut to the desired shape. The pull-tabs canfurther be reinforced pull-tabs, texturized pull-tabs, glow-in-the darkpull-tabs, and so forth.

The bag described herein can be produced by any suitable means known inthe art. For example, the joining of the front and back panels can beaccomplished by various conventional techniques, such as adhesivebonding, thermal bonding, ultrasonic bonding, welding, and so forth. Inanother embodiment, the panels are connected with mechanical fasteningsystems, such as sewing, stapling, riveting, and so forth.

In one embodiment, the bags are also formed from a continuous roll ofmaterial having a pre-formed gusset and perforations. At the appropriatepoint during the process the pre-formed and pre-printed pull-tabs, stillin roll-form, are blown onto the bag film, such as with the use of anautomatic applicator timed to match the speed of the bag formation.Sealing of the two panels at the side seam, such as with heat andcompression, causes the bags to break apart. In another embodiment, thebags are made individually.

In all instances, it is important that adequate welds or seals areproduced at all locations. A combination of time, temperature, pressure,seal area and/or bag film materials may be used to accomplish anadequate seal as is known in the art. Seals are tested using standardindustry methods, although seal strength requirements vary by individualspecifications, depending on consumer, product and equipment needs.Strength tests are performed not only on the bag and handle seal, butalso on both side seams (including gusset area seals), as well as theperforations by methods known in the art. In some instances, an AMTSSintech 1” made by MTS Systems Corporation in Minneapolis, Minn. is usedto test seal and perforation strength.

The adhesive-backed pull-tab of the present invention is designed to behooked by any suitable means that allows a user to then pull on thepull-tab with sufficient, albeit minimal force, in the appropriatedirection to cause the perforations on the bag to tear, creating anopening through which the contents within are exposed and accessible.This design allows a person to utilize a larger muscle group as comparedto the muscles needed to produce a pinch force. As a result, thepull-tab of the present invention provides ease of opening to those withreduced hand strength, whether through disability, age or illness. Afterthe package is open, the consumer may remove one or more products. Afterthe product(s) is removed, the consumer can easily re-secure thepull-tab or strip to the bag by simply pressing on the pull-tab, thusdiscouraging or preventing products from falling out.

The pull-tabs of the present invention can be used on any size package,including trial-sized flexible packages that contain only one product tovery large packages. Perforations designed to be used in combinationwith the pull-tab are not limited to any one configuration and can bealigned in any manner in relation to the pull-tab that allows for easeof opening in any number of combinations. In most embodiments, thepull-tab covers two substantially parallel perforations or is otherwiselocated at a perforation junction, narrowest portion of a curvedperforation line or at a point of minimum distance between two separateperforation lines.

Although specific embodiments have been illustrated and describedherein, it will be appreciated by those of ordinary skill in the artthat any arrangement which is calculated to achieve the same purpose maybe substituted for the specific embodiment shown. This application isintended to cover any adaptations or variations of the presentinvention. Therefore, it is manifestly intended that this invention belimited only by the claims and the equivalents thereof.

1. A package comprising a bag having lines of weakness and a pull-tabopener secured to the bag proximate to the lines of weakness, thepull-tab opener having a pull-tab opening integral therewith, whereinthe pull-tab opening is designed to be hooked with hooking means.
 2. Thepackage of claim 1 wherein the pull-tab opener is a reusable pull-tabopener secured to the bag with reusable securing means or a combinationof reusable securing means and permanent securing means.
 3. The packageof claim 1 wherein the lines of weakness include two substantiallyparallel lines of perforations and a slit or third line of perforationslocated substantially perpendicular to and in between the twosubstantially parallel lines of perforations at one end.
 4. The packageof claim 3 wherein the package is comprised of six panels arranged in arectangular configuration and the substantially parallel lines ofperforations either extend across a portion of two adjacent panels orare contained on a single panel.
 5. The package of claim 1 wherein thepull-tab opener conceals only a portion or none of the lines ofweakness.
 6. The package of claim 1 wherein at least a portion of thelines of weakness are not substantially parallel.
 7. The package ofclaim 6 wherein the lines of weakness include a curved portion.
 8. Thepackage of claim 7 wherein the lines of weakness form a U-shape havingan area of maximum bend and the pull-tab is located in the area ofmaximum bend.
 9. The package of claim 1 wherein the lines of weaknessare non-intersecting lines having a minimum separation distance.
 10. Thepackage of claim 9 wherein a slit or additional lines of weakness arepresent at the minimum separation distance to join the non-intersectinglines of weakness and the pull-tab conceals some or all of the minimumseparation distance.
 11. The package of claim 1 wherein the lines ofweakness are intersecting lines which form a V-shape having aperforation point and the pull-tab opener conceals the perforationpoint.
 12. The package of claim 1 wherein the pull-tab opening is afinger-sized opening and the hooking means comprises one to threefingers or an object having a maximum diameter not greater than abouteight (8) cm.
 13. The package of claim 1 wherein the pull-tab opening islarger than a finger-sized opening and the hooking means includes ahand.
 14. A bag, comprising: a plurality of panels; lines of weaknesslocated on one or more of the plurality of panels, the lines of weaknessconfigured to form one or more flaps when torn; and one or more reusablepull-tabs secured to the one or more flaps and positioned to tear openthe lines of weakness when pulled on with sufficient force, the one ormore pull-tabs each having a pull-tab opening on one end, each pull-tabopening designed to be hooked with a hooking means, wherein the one ormore reusable pull-tab openers are secured to the bag with reusablesecuring means or a combination of reusable securing means and permanentsecuring means, wherein the permanent securing means has a strengthgreater than a tear force required to separate the lines of weakness.15. The bag of claim 14 wherein the one or more reusable pull-tabopeners are laminated.
 16. The bag of claim 14, wherein the bag and oneor more reusable pull-tab openers are made from a polymeric plasticfilm, paper or a paper composite.
 17. The bag of claim 14 furthercomprising markings to convey instructions on how to use the pull-tabopener to access contents within the bag.
 18. A sealed containercomprising: a flexible bag having lines of weakness; at least oneproduct disposed within the bag; and a pull-tab opener secured to thebag proximate to the lines of weakness wherein the pull-tab opener has apull-tab opening configured to allow a user to hook the pull-tab openerthrough the pull-tab opening.
 19. The sealed container of claim 18wherein the bag contains compressed personal care products which can beof different types and sizes.
 20. The sealed container of claim 19further comprising a second pull-tab opener secured to the bag, whereineach pull-tab opener provides access to a different type or size ofpersonal care product.